Bucket chain excavator: Failure analysis and redesign of the counterweight boom supporting truss columns
Abstract
The supporting truss of the counterweight boom is a vital part of the bucket chain excavator's (BCE) superstructure. The occurrence and propagation of cracks in the supporting truss columns' heads may lead to BCE collapse. The goals of the study presented in this paper were to: (a) diagnose the cause of cracks occurrence; (b) define the reconstruction design of the supporting truss columns and (c) validate the reconstructed structure by numerical-experimental analysis. In order to clarify the causes of cracks occurrence, experimental investigations were performed with the purpose of defining the chemical composition, tensile properties, impact toughness and macrohardness of the columns' material. Metallographic examinations were also conducted. Based on the results of finite elements analyses (FEA) and experimental analyses it can be concluded that cracks are caused by the 'design-in' defects. The redesign solution enabled repair and reconstruction in field conditions, without previous...ly dismantling any substructure of the BCE superstructure. Thereby the time required for performing reconstruction is shortened and indirect costs due to the BCE downtime are considerably diminished. Both the experimental analysis of the stress state of the reconstructed columns in regular working conditions and the failure-free exploitation have confirmed the validity of the reconstruction design, while the BCE excavated approximately 8.5 x 10(6) t of coal and 1.8 x 10(6) m(3) of overburden after the reconstruction.
Keywords:
Redesign / Finite element analysis / Failure diagnostics / Experimental validation / Bucket chain excavator superstructureSource:
Engineering Failure Analysis, 2013, 32, 322-333Publisher:
- Pergamon-Elsevier Science Ltd, Oxford
Funding / projects:
- Sustainability and improvement of mechanical systems in energetic, material handling and conveying by using forensic engineering, environmental and robust design (RS-MESTD-Technological Development (TD or TR)-35006)
DOI: 10.1016/j.engfailanal.2013.04.012
ISSN: 1350-6307
WoS: 000320736800030
Scopus: 2-s2.0-84877315046
Collections
Institution/Community
Inovacioni centarTY - JOUR AU - Bošnjak, Srđan AU - Petković, Zoran D. AU - Atanasovska, Ivana AU - Milojević, Goran AU - Mihajlović, Vaso M. PY - 2013 UR - https://machinery.mas.bg.ac.rs/handle/123456789/1724 AB - The supporting truss of the counterweight boom is a vital part of the bucket chain excavator's (BCE) superstructure. The occurrence and propagation of cracks in the supporting truss columns' heads may lead to BCE collapse. The goals of the study presented in this paper were to: (a) diagnose the cause of cracks occurrence; (b) define the reconstruction design of the supporting truss columns and (c) validate the reconstructed structure by numerical-experimental analysis. In order to clarify the causes of cracks occurrence, experimental investigations were performed with the purpose of defining the chemical composition, tensile properties, impact toughness and macrohardness of the columns' material. Metallographic examinations were also conducted. Based on the results of finite elements analyses (FEA) and experimental analyses it can be concluded that cracks are caused by the 'design-in' defects. The redesign solution enabled repair and reconstruction in field conditions, without previously dismantling any substructure of the BCE superstructure. Thereby the time required for performing reconstruction is shortened and indirect costs due to the BCE downtime are considerably diminished. Both the experimental analysis of the stress state of the reconstructed columns in regular working conditions and the failure-free exploitation have confirmed the validity of the reconstruction design, while the BCE excavated approximately 8.5 x 10(6) t of coal and 1.8 x 10(6) m(3) of overburden after the reconstruction. PB - Pergamon-Elsevier Science Ltd, Oxford T2 - Engineering Failure Analysis T1 - Bucket chain excavator: Failure analysis and redesign of the counterweight boom supporting truss columns EP - 333 SP - 322 VL - 32 DO - 10.1016/j.engfailanal.2013.04.012 ER -
@article{ author = "Bošnjak, Srđan and Petković, Zoran D. and Atanasovska, Ivana and Milojević, Goran and Mihajlović, Vaso M.", year = "2013", abstract = "The supporting truss of the counterweight boom is a vital part of the bucket chain excavator's (BCE) superstructure. The occurrence and propagation of cracks in the supporting truss columns' heads may lead to BCE collapse. The goals of the study presented in this paper were to: (a) diagnose the cause of cracks occurrence; (b) define the reconstruction design of the supporting truss columns and (c) validate the reconstructed structure by numerical-experimental analysis. In order to clarify the causes of cracks occurrence, experimental investigations were performed with the purpose of defining the chemical composition, tensile properties, impact toughness and macrohardness of the columns' material. Metallographic examinations were also conducted. Based on the results of finite elements analyses (FEA) and experimental analyses it can be concluded that cracks are caused by the 'design-in' defects. The redesign solution enabled repair and reconstruction in field conditions, without previously dismantling any substructure of the BCE superstructure. Thereby the time required for performing reconstruction is shortened and indirect costs due to the BCE downtime are considerably diminished. Both the experimental analysis of the stress state of the reconstructed columns in regular working conditions and the failure-free exploitation have confirmed the validity of the reconstruction design, while the BCE excavated approximately 8.5 x 10(6) t of coal and 1.8 x 10(6) m(3) of overburden after the reconstruction.", publisher = "Pergamon-Elsevier Science Ltd, Oxford", journal = "Engineering Failure Analysis", title = "Bucket chain excavator: Failure analysis and redesign of the counterweight boom supporting truss columns", pages = "333-322", volume = "32", doi = "10.1016/j.engfailanal.2013.04.012" }
Bošnjak, S., Petković, Z. D., Atanasovska, I., Milojević, G.,& Mihajlović, V. M.. (2013). Bucket chain excavator: Failure analysis and redesign of the counterweight boom supporting truss columns. in Engineering Failure Analysis Pergamon-Elsevier Science Ltd, Oxford., 32, 322-333. https://doi.org/10.1016/j.engfailanal.2013.04.012
Bošnjak S, Petković ZD, Atanasovska I, Milojević G, Mihajlović VM. Bucket chain excavator: Failure analysis and redesign of the counterweight boom supporting truss columns. in Engineering Failure Analysis. 2013;32:322-333. doi:10.1016/j.engfailanal.2013.04.012 .
Bošnjak, Srđan, Petković, Zoran D., Atanasovska, Ivana, Milojević, Goran, Mihajlović, Vaso M., "Bucket chain excavator: Failure analysis and redesign of the counterweight boom supporting truss columns" in Engineering Failure Analysis, 32 (2013):322-333, https://doi.org/10.1016/j.engfailanal.2013.04.012 . .